1998 DODGE RAM 1500 Locks

ENGINE BLOCK
STANDARD PROCEDURE
STANDARD PROCEDURE - CYLINDER BLOCK
REFACING
(1) The combustion deck can be refaced twice. The
first reface should be 0.25 mm (0.0098 inch). If addi-
tional refacing is required, an additional 0.25 mm
(0.0098 inch) can be removed. Total allowed refacing
is 0.50 mm (0.0197 inch) - (Fig. 44).
(2) The upper right corner of the rear face of the
block must be stamped with a X when the block is
refaced to 0.25 mm (0.0098 inch). A second X must be
stamped beside the first when the block is refaced to
0.50 mm (0.0197 inch) - (Fig. 45).
(3) Consult the parts catalog for the proper head
gaskets which must be used with refaced blocks to
ensure proper piston-to-valve clearance.
STANDARD PROCEDURE - CYLINDER BORE -
DE-GLAZE
(1) New piston rings may not seat in glazed cylin-
der bores.
(2) De-glazing gives the bore the correct surface
finish required to seat the rings. The size of the bore
is not changed by proper de-glazing.
(3) Cover the lube and tappet holes in the top of
the block with waterproof tape.
(4) It crankshaft is installed, wrap connecting rod
journals with clean cloth. Cover cloth with water-
proof tape.
(5) A correctly honed surface will have a cross-
hatch appearance with the lines at 15É to 25É angles
(Fig. 46). For the rough hone, use 80 grit honing
stones. To finish hone, use 280 grit honing stones.
Fig. 44 Refacing Dimensions of the Cylinder Block
CYLINDER BLOCK REFACING DIMENSIONS
DIMENSION(A(
1st Reface 0.25mm (0.0098 in.)
2nd Reface 0.25mm (0.0098 in.)
Dim (A) Total 0.50 mm (0.0197 in.)
DIMENSION(B(
Dim.9B9(STD.)323.00 mm   0.10
mm(12.7165 in.  
0.0039 in.)
1st Reface322.75 mm   0.10
mm(12.7067 in.  
0.0039 in.)
2nd Reface322.50 mm   0.10
mm(12.6968 in.  
0.0039 in.)
Fig. 45 Stamp Block after Reface
Fig. 46 Cylinder Bore Crosshatch Pattern
9 - 264 ENGINE 5.9L DIESELDR

CRANKSHAFT OIL SEAL - FRONT
REMOVAL
(1) Disconnect both battery negative cables.
(2) Raise vehicle on hoist.
(3) Partially drain engine coolant into container
suitable for re-use (Refer to 7 - COOLING - STAN-
DARD PROCEDURE).
(4) Lower vehicle.
(5) Remove radiator upper hose.
(6) Disconnect coolant recovery bottle from radia-
tor filler neck and lift bottle off of fan shroud.
(7) Disconnect windshield washer pump supply
hose and electrical connections and lift washer bottle
off of fan shroud.
(8)
Remove the fan shroud-to-radiator mounting bolts.
(9)Remove viscous fan/drive assembly. (Refer to 7 -
COOLING/ENGINE/RADIATOR FAN - REMOVAL).
(10) Remove cooling fan shroud and fan assembly
from the vehicle.
(11) Remove the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(12) Remove the cooling fan support/hub from the
front of the engine.
(13) Raise the vehicle on hoist.
(14) Remove the crankshaft damper and speed
indicator ring.
(15) Remove power steering pump.
(16) Remove accessory drive belt tensioner.
(17) Remove the gear cover-to-housing bolts and
gently pry the cover away from the housing, taking
care not to mar the gasket surfaces. Remove crank
seal dust shield with cover.
(18) Support the cover on a flat work surface with
wooden blocks (Fig. 68), and using a suitable punch
and hammer, drive the old seal out of the cover from
the back side of the cover to the front side (Fig. 68).
INSTALLATION
(1) Clean cover and housing gasket mating sur-
faces. Use a suitable scraper and be careful not to
damage the gear housing surface. Remove any old
sealer from the oil seal bore. Thoroughly clean the
front seal area of the crankshaft. The seal lip and the
sealing surface on the crankshaft must be free from
all oil residue to prevent seal leaks.
(2) Inspect the gear housing and cover for cracks
and replace if necessary. Carefully straighten any
bends or imperfections in the gear cover with a ball-
peen hammer on a flat surface. Inspect the crank-
shaft front journal for any grooves or nicks that
would affect the integrity of the new seal.
(3) Apply a bead of MopartStud & Bearing Mount
to the outside diameter of the seal. Do not lubricate
the inside diameter of the new seal.(4)
With the cover supported by wood blocks, install
the seal into the rear of the cover using crankshaft seal
installer Special Tool 8281 and driver handle C-4171
(Fig. 69). Strike the driver handle until the installation
tool bottoms out on the inside of the cover.
CAUTION: Do not distort or damage seal.
(5) Install the plastic seal pilot (provided with seal
kit) into the crankshaft seal.
Fig. 68 Removing Seal from Cover
1 - PUNCH
Fig. 69 Installing Seal Into Cover With Tool 8281
1 - SEAL INSTALLER 8281
2 - DRIVER HANDLE C4171
3 - SEAL
DRENGINE 5.9L DIESEL 9 - 275

(d) Insert special fuel line removal tool (Snap-On
number FIH 9055-1 or equivalent) into fuel line
(Fig. 14). Use tool to release locking fingers in end
of line.
(e) With special tool still inserted, pull fuel line
from fuel rail.
(f) After disconnection, locking fingers will
remain within quick-connect fitting at end of fuel
line.
(10) Disconnect quick-connect fitting from fuel sys-
tem component being serviced.
CONNECTING
(1) Inspect quick-connect fitting body and fuel sys-
tem component for damage. Replace as necessary.
(2) Prior to connecting quick-connect fitting to
component being serviced, check condition of fitting
and component. Clean parts with a lint-free cloth.
Lubricate with clean engine oil.
(3) Insert quick-connect fitting into fuel tube or
fuel system component until built-on stop on fuel
tube or component rests against back of fitting.
(4) Continue pushing until a click is felt.
(5) Single-tab type fitting: Push new tab down
until it locks into place in quick-connect fitting.
(6) Verify a locked condition by firmly pulling on
fuel tube and fitting (15-30 lbs.).
(7) Latch Clip Equipped: Install latch clip (snaps
into position).If latch clip will not fit, this indi-
cates fuel line is not properly installed to fuel
rail (or other fuel line). Recheck fuel line con-
nection.
(8) Connect negative cable to battery.
(9) Start engine and check for leaks.
FUEL PUMP
DESCRIPTION
The electric fuel pump is located inside of the fuel
pump module. A 12 volt, permanent magnet, electric
motor powers the fuel pump. The electric fuel pump
is not a separate, serviceable component.
OPERATION
Voltage to operate the electric pump is supplied
through the fuel pump relay.
Fuel is drawn in through a filter at the bottom of
the module and pushed through the electric motor
gearset to the pump outlet.
Check Valve Operation:The bottom section of
the fuel pump module contains a one-way check
valve to prevent fuel flow back into the tank and to
maintain fuel supply line pressure (engine warm)
when pump is not operational. It is also used to keep
the fuel supply line full of gasoline when pump is not
operational. After the vehicle has cooled down, fuel
pressure may drop to 0 psi (cold fluid contracts), but
liquid gasoline will remain in fuel supply line
between the check valve and fuel injectors.Fuel
pressure that has dropped to 0 psi on a cooled
down vehicle (engine off) is a normal condition.
The electric fuel pump is not a separate, service-
able component.
FUEL PUMP MODULE
DESCRIPTION
The fuel pump module assembly is located on the
top of the fuel tank (Fig. 1). The complete assembly
contains the following components:
²A combination fuel filter/fuel pressure regulator
²A separate fuel pick-up, or inlet filter
²An electric fuel pump
²A lockring to retain pump module to tank
²A soft gasket between tank flange and module
²A fuel gauge sending unit (fuel level sensor)
²Fuel line connection
The fuel gauge sending unit may be serviced sepa-
rately. If the electrical fuel pump, primary inlet filter,
fuel filter or fuel pressure regulator require service,
the fuel pump module must be replaced.
OPERATION
Refer to Fuel Pump, Inlet Filter, Fuel Filter / Fuel
Pressure Regulator and Fuel Gauge Sending Unit.
Fig. 14 FUEL LINE DISCONNECTION USING
SPECIAL TOOL
1 - SPECIAL FUEL LINE TOOL
2 - FUEL LINE
3 - FUEL RAIL
DRFUEL DELIVERY - GAS 14 - 11
QUICK CONNECT FITTING (Continued)

REMOVAL
The fuel pump relay is located in the Power Distri-
bution Center (PDC) (Fig. 13). Refer to label on PDC
cover for relay location.
(1) Remove PDC cover.
(2) Remove relay from PDC.
(3) Check condition of relay terminals and PDC
connector terminals for damage or corrosion. Repair
if necessary before installing relay.
(4) Check for pin height (pin height should be the
same for all terminals within the PDC connector).
Repair if necessary before installing relay.
INSTALLATION
The fuel pump relay is located in the Power Distri-
bution Center (PDC). Refer to label on PDC cover for
relay location.
(1) Install relay to PDC.
(2) Install cover to PDC.
IDLE AIR CONTROL MOTOR
DESCRIPTION
A separate IAC motor is not used with the 5.7L V-8
engine.
The IAC stepper motor is mounted to the throttle
body, and regulates the amount of air bypassing the
control of the throttle plate. As engine loads and
ambient temperatures change, engine rpm changes.
A pintle on the IAC stepper motor protrudes into apassage in the throttle body, controlling air flow
through the passage. The IAC is controlled by the
Powertrain Control Module (PCM) to maintain the
target engine idle speed.
OPERATION
A separate IAC motor is not used with the 5.7L V-8
engine.
At idle, engine speed can be increased by retract-
ing the IAC motor pintle and allowing more air to
pass through the port, or it can be decreased by
restricting the passage with the pintle and diminish-
ing the amount of air bypassing the throttle plate.
The IAC is called a stepper motor because it is
moved (rotated) in steps, or increments. Opening the
IAC opens an air passage around the throttle blade
which increases RPM.
The PCM uses the IAC motor to control idle speed
(along with timing) and to reach a desired MAP dur-
ing decel (keep engine from stalling).
The IAC motor has 4 wires with 4 circuits. Two of
the wires are for 12 volts and ground to supply elec-
trical current to the motor windings to operate the
stepper motor in one direction. The other 2 wires are
also for 12 volts and ground to supply electrical cur-
rent to operate the stepper motor in the opposite
direction.
To make the IAC go in the opposite direction, the
PCM just reverses polarity on both windings. If only
1 wire is open, the IAC can only be moved 1 step
(increment) in either direction. To keep the IAC
motor in position when no movement is needed, the
PCM will energize both windings at the same time.
This locks the IAC motor in place.
In the IAC motor system, the PCM will count
every step that the motor is moved. This allows the
PCM to determine the motor pintle position. If the
memory is cleared, the PCM no longer knows the
position of the pintle. So at the first key ON, the
PCM drives the IAC motor closed, regardless of
where it was before. This zeros the counter. From
this point the PCM will back out the IAC motor and
keep track of its position again.
When engine rpm is above idle speed, the IAC is
used for the following:
²Off-idle dashpot (throttle blade will close quickly
but idle speed will not stop quickly)
²Deceleration air flow control
²A/C compressor load control (also opens the pas-
sage slightly before the compressor is engaged so
that the engine rpm does not dip down when the
compressor engages)
²Power steering load control
The PCM can control polarity of the circuit to con-
trol direction of the stepper motor.
Fig. 13 PDC LOCATION
1 - BATTERY
2 - INTEGRATED POWER MODULE (IPM)
14 - 28 FUEL INJECTION - GASDR
FUEL PUMP RELAY (Continued)

NOTE: When servicing the steering wheel after
removing the old bolt a new bolt must be used
when installing.
NOTE: When servicing the coupler a new bolt must
be used when installing.
DIAGNOSIS AND TESTING - STEERING
COLUMN
If the vehicle is involved in a front end collision/the
air bag has deployed the column must be inspected.
This inspection will determine if the Column has col-
lapsed. Inspect the column mounting capsules visu-
ally and manually push and pull them to check for
separation or fractures. If capsules are fractured or
have moved the column MUST be replaced.
REMOVAL
WARNING: BEFORE SERVICING THE STEERING
COLUMN THE AIRBAG SYSTEM MUST BE DIS-
ARMED. REFER TO ELECTRICAL RESTRAINT SYS-
TEM FOR SERVICE PROCEDURES. FAILURE TO DO
SO MAY RESULT IN ACCIDENTAL DEPLOYMENT OF
THE AIRBAG AND POSSIBLE PERSONAL INJURY.CAUTION: All fasteners must be torqued to specifi-
cation to ensure proper operation of the steering
column.
(1) Position the front wheelsstraight ahead.
(2) Disconnect the negative (ground) cable from
the battery.
(3) Remove the two switches from the steering
wheel.
(4) Remove the airbag, (Refer to 8 - ELECTRICAL/
RESTRAINTS/DRIVER AIRBAG - REMOVAL).
(5) Remove the steering wheel with special tool
CJ98±1 or an appropriate steering wheel puller.
CAUTION: Ensure the puller bolts are fully engaged
into the steering wheel and not into the clock-
spring, before attempting to remove the wheel. Fail-
ure to do so may damage the steering wheel/
clockspring.
(6) Remove the steering column opening cover
(Refer to 23 - BODY/INSTRUMENT PANEL/STEER-
ING COLUMN OPENING COVER - REMOVAL).
(7) Remove the tilt lever.
(8) Remove the column shrouds (Fig. 2).
(9) Remove the clock spring, (Refer to 8 - ELEC-
TRICAL/RESTRAINTS/CLOCKSPRING -
REMOVAL).
(10) Disconnect the wiring harness to the column.
Fig. 1 STEERING COLUMN
1 - LOCK CYLINDER
2 - GEAR SHIFT LEVER
3 - MOUNTING HOLES
4 - STEERING COLUMN
5 - TILT LEVER
Fig. 2 UPPER & LOWER SHROUDS
1 - UPPER SHROUD
2 - LOWER SHROUD
DRCOLUMN 19 - 7
COLUMN (Continued)

(17) Remove the steering column assembly from
the vehicle. (Fig. 7)
INSTALLATION
WARNING: BEFORE SERVICING THE STEERING
COLUMN THE AIRBAG SYSTEM MUST BE DIS-
ARMED. REFER TO ELECTRICAL RESTRAINT SYS-
TEM FOR SERVICE PROCEDURES. FAILURE TO DO
SO MAY RESULT IN ACCIDENTAL DEPLOYMENT OF
THE AIRBAG AND POSSIBLE PERSONAL INJURY.
CAUTION: All fasteners must be torqued to specifi-
cation to ensure proper operation of the steering
column.
(1) Position the steering column on the dash panel
support and loosely install the mounting nuts.
(2) Firmly slide the steering column upward
against the studs in dash panel and hand tighten the
nuts.
(3) Install the steering shaft coupler on the steer-
ing shaft and loosely install anewbolt.
(4) Center steering column in dash opening and
tighten mounting nuts to 28 N´m (250 in. lbs.).
NOTE: Torque the upper left nut first then the lower
right nut. Then torque the lower left nut then the
upper right nut.
NOTE: A new bolt must be used for reinstallation.
(5) Tighten the coupler bolt to 57 N´m (42 ft. lbs.).(6) Install a new brake light switch (Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
BRAKE LAMP SWITCH - REMOVAL).
(7) Install the shifter cable. (Refer to 21 - TRANS-
MISSION/TRANSAXLE/AUTOMATIC - 32RH/GEAR
SHIFT CABLE - INSTALLATION)
(8) Connect the wiring harness to the column.
(9) Install the SKIM module.
(10) Install the clockspring(Refer to 8 - ELECTRI-
CAL/RESTRAINTS/CLOCKSPRING - REMOVAL).
(11) Install the shrouds.
(12) Install the steering column opening cover
(Refer to 23 - BODY/INSTRUMENT PANEL/STEER-
ING COLUMN OPENING COVER - INSTALLA-
TION).
(13) Align the spline on the wheel hub to shaft.
(14) Then install the steering wheel and install a
newbolt. Tighten the bolt to 61 N´m (45 ft. lbs.).
(15) Install the airbag (Refer to 8 - ELECTRICAL/
RESTRAINTS/DRIVER AIRBAG - INSTALLATION).
(16) Install the two steering wheel switches.
(17) Install the tilt lever handle.
(18) Install the negative battery terminal.
(19) Test the operation of the horn, Electronic
PRNDL Indicator, lights and any other functions that
are steering column operated.
IGNITION SWITCH
DESCRIPTION
The ignition switch is located on the steering col-
umn. It is used as the main on/off switching device
for most electrical components. The mechanical key
cylinder is used to engage/disengage the electrical
ignition switch.
OPERATION
Vehicles equipped with an automatic trans-
mission and a steering column mounted shifter:
an interlock device is located within the shift cable.
This interlock device is used to lock the transmission
shifter in the PARK position when the key cylinder is
in any position and the brake pedal is not depressed.
DIAGNOSIS AND TESTING - IGNITION SWITCH
TEST AND REPAIR
If the key removal effort is excessive on a vehicle
with a automatic transmission first adjust the shift
linkage, (Refer to 21 - TRANSMISSION/TRANS-
AXLE/AUTOMATIC - 46RE/GEAR SHIFT CABLE -
ADJUSTMENTS).
If the ignition switch effort is excessive remove the
ignition key cylinder from the steering column. (Refer
to 19 - STEERING/COLUMN/LOCK CYLINDER
Fig. 7 STEERING COLUMN
1 - Steering Wheel
2 - Key Cylinder
3 - Gear Shift Lever
4 - Steering Column
5 - Tilt Lever Cable
DRCOLUMN 19 - 9
COLUMN (Continued)

HOUSING - REMOVAL). Check the turning effort of
the key cylinder. If the ignition key cylinder effort is
excessive replace the key cylinder.
REMOVAL
SERVICE PRECAUTIONS
NOTE: The steering column on vehicles equipped
with an automatic transmission is not equipped
with an internal locking shaft with the ignition cyl-
inder. Alternative methods of locking the steering
wheel for service will have to be used.
The tilt and standard column (Fig. 8) have been
designed to be serviced as an assembly; without wir-
ing, switches, shrouds, steering wheel, etc. Most
steering column components can be serviced without
removing the steering column from the vehicle.
Safety goggles should be worn at all times when
working on steering columns.
To service the steering wheel, switches or airbag,
Refer to Electrical Restraints and follow all WARN-
INGS and CAUTIONS.
WARNING: THE AIRBAG SYSTEM IS A SENSITIVE,
COMPLEX ELECTRO-MECHANICAL UNIT. BEFORE
ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALL
THE AIRBAG SYSTEM COMPONENTS YOU MUST
FIRST DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE. THEN WAIT TWO
MINUTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE. FAILURE TO DO SO COULD RESULT IN
ACCIDENTAL DEPLOYMENT OF THE AIRBAG ANDPOSSIBLE PERSONAL INJURY. THE FASTENERS,
SCREWS, AND BOLTS, ORIGINALLY USED FOR
THE AIRBAG COMPONENTS, HAVE SPECIAL COAT-
INGS AND ARE SPECIFICALLY DESIGNED FOR THE
AIRBAG SYSTEM. THEY MUST NEVER BE
REPLACED WITH ANY SUBSTITUTES. ANYTIME A
NEW FASTENER IS NEEDED, REPLACE WITH THE
CORRECT FASTENERS PROVIDED IN THE SERVICE
PACKAGE OR FASTENERS LISTED IN THE PARTS
BOOKS.
CAUTION: Do not hammer on steering column
shaft. This may cause damage to the shaft or bear-
ing.
CAUTION: Do not attempt to remove the pivot bolts
to disassemble the tilting mechanism.
The ignition key must be in the key cylinder for
cylinder removal. The key cylinder must be removed
first before removing ignition switch.
(1) Remove the negative (ground) cable from the
battery.
(2) Disable the airbag, (Refer to 8 - ELECTRICAL/
RESTRAINTS/DRIVER AIRBAG - REMOVAL).
(3) Remove the lower and upper shrouds.
(4) Remove key cylinder. (Refer to 19 - STEER-
ING/COLUMN/LOCK CYLINDER HOUSING -
REMOVAL).
(5) Disconnect the lower clockspring connectors.
(6) Remove the wire retainer from the tilt lever
bracket.
(7) Remove the tilt lever mounting screws to gain
access to the ignition switch mounting screws. (Fig.
9)
Fig. 8 STEERING COLUMN
1 - KEY CYLINDER
2 - GEAR SHIFT LEVER
3 - MOUNTING HOLES
4 - STEERING COLUMN
5 - IGNITION SWITCH
Fig. 9 IGNITION SWITCH WITH TILT
1 - IGNITION SWITCH
2 - TILT LEVER MECHANISM
19 - 10 COLUMNDR
IGNITION SWITCH (Continued)

(8) For columns without tilt remove the bracket to
gain access to the ignition switch mounting screws.
(Fig. 10)
(9) Disconnect the electrical connector at rear of
ignition switch (Fig. 11).
(10) Remove ignition switch mounting screw.
(11) Using a small screwdriver, push on locking
tab and remove switch from steering column.
INSTALLATION
The ignition key must be in the key cylinder for
cylinder removal. The key cylinder must be removed
first before installing ignition switch.
(1) Before installing ignition switch, rotate the slot
in the switch to the ON position.(2) Connect the electrical connector to rear of the
ignition switch. Make sure that locking tabs are fully
seated into wiring connector.
(3) Position switch to column and install the
mounting screw. Tighten screw to 3 N´m (26 in. lbs.).
(4) Install the tilt lever bracket mounting screws.
Tighten screws to 4.5 N´m (40 in. lbs.).
(5) If the column is non-tilt install the bracket.
Tighten screws to 4.5 N´m (40 in. lbs.) (Fig. 10)
(6) Position the wire retainer into the tilt lever
bracket.
(7) Reconnect the lower clockspring connectors.
(8) Install the key cylinder.
(9) Install steering column upper and lower
shrouds.
(10) Enable the airbag system. (Refer to 8 - ELEC-
TRICAL/RESTRAINTS/DRIVER AIRBAG - INSTAL-
LATION).
KEY-IN IGNITION SWITCH
DESCRIPTION
The key-in ignition switch is integral to the igni-
tion switch, which is mounted on the left side of the
steering column. It closes a path to ground for the
Central Timer Module (CTM) when the ignition key
is inserted in the ignition key cylinder and the driver
door ajar switch is closed (driver door is open). The
key-in ignition switch opens the ground path when
the key is removed from the ignition key cylinder.
The ground path is also opened when the driver door
ajar switch is open (driver door is closed).
The key-in ignition switch cannot be repaired and,
if faulty or damaged, the entire ignition switch must
be replaced, (Refer to 19 - STEERING/COLUMN/IG-
NITION SWITCH - REMOVAL).
DIAGNOSIS AND TESTING - IGNITION SWITCH
AND KEY LOCK CYLINDER
ELECTRICAL DIAGNOSIS
For ignition switch electrical schematics, refer to
Ignition Switch in the appropriate section of Electri-
cal Wiring Diagrams.
MECHANICAL DIAGNOSIS (KEY DIFFICULT TO
ROTATE)
(Refer to 19 - STEERING/COLUMN/IGNITION
SWITCH - DIAGNOSIS AND TESTING).
Fig. 10 IGNITION SWITCH WITHOUT TILT
1 - Ignition Switch Mounting Screws
2 - Non-Tilt Mounitng Bracket Screws
Fig. 11 IGNITION SWITCH
1 - Ignition Switch
2 - Ignition Switch Mounting Screws
DRCOLUMN 19 - 11
IGNITION SWITCH (Continued)